Comparison of Effect of Cutting Parameters during Dry and Wet Turning of AISI 1020 Steel

Abstract

Cutting fluids application in turning operation helps to remove heat during cutting, to achieve better tool life, and to facilitate flushing of chips. On the other hand dry turning is important due to saving cost of cutting fluids, safety of operator and clean environment. Producing parts with a better surface finish is the major challenges in manufacturing industry. In this work, experiment was conducted to compare the effect of cutting parameters (spindle speed, feed rate and depth of cut) on surface roughness and to investigate the optimum cutting parameters for surface roughness during dry and wet turning of AISI 1020 steel using cemented carbide tool on CNC lathe machine. Analysis of cutting temperature, tool life, and machining cost were also done to for dry and wet turning. Surface roughness and cutting temperature were measured by VOGEL surface roughness tester and infrared thermometer respectively. L9 Taguchi orthogonal array design was selected for design of experiment. The effect of each cutting parameters on responses were identified by the analysis of variance (ANOVA). The result shows that Surface roughness decreased with increasing of spindle speed, and decreasing feed rate and depth of cut. Increasing in cutting parameters was resulted in increased cutting temperature and reduced tool life. But application of coolant highly minimize the cutting temperature and increase tool life. Surface roughness, cutting temperature and tool life are highly affected by spindle speed both in dry and wet turning, while total machining cost highly affected by spindle speed in dry turning and by feed rate in wet turning. Wet turning results in lower surface roughness, cutting temperature and longer tool life, but machining cost of wet turning was 56% greater than that of dry turningCutting Fluids Application In Turning Operation Helps To Remove Heat During Cutting, To Achieve Better Tool Life, And To Facilitate Flushing Of Chips. On The Other Hand Dry Turning Is Important Due To Saving Cost Of Cutting Fluids, Safety Of Operator And Clean Environment. Producing Parts With A Better Surface Finish Is The Major Challenges In Manufacturing Industry. In This Work, Experiment Was Conducted To Compare The Effect Of Cutting Parameters (Spindle Speed, Feed Rate And Depth Of Cut) On Surface Roughness And To Investigate The Optimum Cutting Parameters For Surface Roughness During Dry And Wet Turning Of Aisi 1020 Steel Using Cemented Carbide Tool On Cnc Lathe Machine. Analysis Of Cutting Temperature, Tool Life, And Machining Cost Were Also Done To For Dry And Wet Turning. Surface Roughness And Cutting Temperature Were Measured By Vogel Surface Roughness Tester And Infrared Thermometer Respectively. L9 Taguchi Orthogonal Array Design Was Selected For Design Of Experiment. The Effect Of Each Cutting Parameters On Responses Were Identified By The Analysis Of Variance (Anova). The Result Shows That Surface Roughness Decreased With Increasing Of Spindle Speed, And Decreasing Feed Rate And Depth Of Cut. Increasing In Cutting Parameters Was Resulted In Increased Cutting Temperature And Reduced Tool Life. But Application Of Coolant Highly Minimize The Cutting Temperature And Increase Tool Life. Surface Roughness, Cutting Temperature And Tool Life Are Highly Affected By Spindle Speed Both In Dry And Wet Turning, While Total Machining Cost Highly Affected By Spindle Speed In Dry Turning And By Feed Rate In Wet Turning. Wet Turning Results In Lower Surface Roughness, Cutting Temperature And Longer Tool Life, But Machining Cost Of Wet Turning Was 56% Greater Than ThatOf Dry Turning